Method for forming end plates and end rings



June 27, 1961 s. w. FARNswoRTH ETAT. 2,989,936

METHOD FOR FORMING END PLATES AND END RINGS Filed June 28, 1957 3 Sheets-Sheet 1 STATION 1I STATION IIL ROEL/CH ATTORNEYS METHOD FOR FORMING END PLATES AND END RINGS Filed June 28. 1957 June-27, 1961 s. w. FARNswoRTH ErAL 3 Sheets-Sheet 2 QE S2 8% be N IIIKAQ .A H @s INVENTORS S/DNEV WEARA/SWORTHa GUSZAVE H. FROEL/CH ATTORNEYS June 27, 1961 2,989,936

S. W. FARNSWORTH ETAL METHOD FOR FORMING END PLATES AND END RINGS Filed June 28, 1957 3 Sheets-Sheet 25 INVENToRs.

I s/DN y w ,f HARA/WORTH a Gus E H. PROEL/CH ATTORNEYS nited States Patent Ooce 2,989,936 Patented June 27, 1961 2,989,936 METHOD FOR FORMING END PLATES AND END RINGS Sidney W. Farnsworth, Upper Montclair, NJ., and Gustave H. Froelich, Torrington, Conn., assignors to The Torrington Manufacturing Company, Torrington,

Conn., a corporation of Connecticut Filed June 28, 1957, Ser. No. 668,672 4 Claims. (Cl. 113-51) The invention relates to blower wheels of the type wherein each wheel comprises a generally cylindrical blade unit, ordinarily formed from sheet metal, and also comprises two sheet metal end members one of which is an end plate and the other of which is an end ring. The end plate and the end ring have at least approximately the same exterior diameter and they are connected with the blade unit by crimping or otherwise.

According to prior practice, the forming of the end rings for blower wheels has been wasteful, as the relatively large circular discs that were punched out to form the rings could not be economically used. In accordance with the present invention, each end plate and the companion end ring which has the same exterior diameter are both formed from a single blank having a diameter but little if any greater than the diameter of a blank previously necessary for making only one of said members.

The drawings show a presently preferred tool assembly adapted for practicing the method of the invention. The said tool assembly and the manner of operation thereof will be described, but it will be understood that the invention is not limited to the details of any particular tool assembly and that the drawings and description are not to be construed as defining or limiting the scope of the invention, the claims forming a part of this specification being relied upon for that purpose.

Of the drawings:

FIG. 1 is a partly schematic longitudinal vertical sectional view of the right portions of the upper and lower units of a tool assembly adapted for practicing the method of the invention, this view yalso showing in vertical section a portion of a metallic strip upon which certain forming operations have been effected by movement of the upper unit of the tool assembly from an upper position to the lower position which is shown. For simplicity of illustration in FIG. 1 and in other ligures, `certain coil springs are indicated by crossed dot-and-dash lines.

FIG. 2 is a plan view of the metallic strip portion shown in section in FIG. 1.

FIG. 2A is a vertical sectional view taken along the line 2A-2A of FIG. 2.

FIG. 3 is a View similar to FIG. 1, but showing the left portion of the tool assembly and the corresponding portion of the metallic strip upon which additional forming operations have been effected.

FIG. 4 is a plan view of the metallic strip portion shown in section in FIG. 3.

FIG. 4A is `a vertical sectional view taken along the line 4A-4A of FIG. 4.

FIG. 5 is a transverse vertical sectional view taken through the center of station V in FIG. 3, but showing the upper unit of the tool yassembly in its upper position. FIG. 5A is a vertical sectional view similar to FIG. 5, but showing only the sheet metal.

FIG. 6 is a View similar to FIG. 5, but showing the upper unit of the tool assembly in an intermediate position. FIG. 7 is a View similar to FIGS. 5 and 6, but showing the upper unit of the tool assembly in its lower position. FIG. 8 is an exploded perspective view showing the two blower wheel parts made in accordance with the method of the invention and also showing a blower wheel blade unit with which said parts are adapted to be assembled.

Referring to the drawings, more particularly FIGS. 1 and 2 thereof, 10 is the bed of the lower stationary unit of a forming tool `assembly and 12 is the head of the vertically reciprocable upper unit of said forming tool assembly. 'Ihe lower and upper units of the tool assembly are carried by a suitable press, not shown, and by the action of the press the upper unit is reciprocated. At longitudinally spaced stations said bed and head carry various cooperating tools to be described, and said tools serve to cut and form a sheet metal strip 14 which is intermittently fed manually or by means, not shown, in timed relationship with the reciprocation of the upper tool, the amount of feed corresponding to the spacing of the stations. When the tool units are constructed and arranged as shown, the strip 14 is fed from lright to left and, upon each downward movement of the upper unit, a cutting or forming operation is effected -at each station. For convenience of illustration, the thickness of the strip 14 is considerably exaggerated in the drawings.

At station I, as shown in FIG. 1, a punch 16 carried by the head 12 cooperates with a die 18 to cut a hole 20 in the strip. Said hole has similar partly circular trailing and leading convex edges 21 and 22 which are closely spaced at the center. The radius of each curved edge 21 and '22 is such that the center of the leading edge 22 is coincident with the center of the trailing edge 21 of the next vadjacent leading hole.

Each two adjacent holes 20 are at opposite sides of and define a strip area 24 which lconstitutes a blank. As will be hereinafter apparent, each blank 24 is utilized to form companion sheet metal members A and B which members have approximately the same external diameters and are respectively an end plate and an end ring. lThese members may be lan end plate and an end ring for a blower wheel yas shown in FIG. 8. Each blank 24 remains connected with the `adjacent blank 24 by longitudinal bands 26, 26 at the edges of the strip 14. The operations at the hereinafter described stations II, HI Iand IV are for the making of the end plate A. The operations at the hereinafter described stations V, VI and VII are for the making ofthe end ring B.

At station II, as shown in FIG. 1, the lower tool unit includes a resistance plunger 28 which is spring biased upwardly within a stationary ring 30. Upward movement is limited by interengaging shoulders on said plunger and ring. When the upper tool unit is in its rupper position, the top face of said plunger 28 is lat the level of the bottom of the strip 14.

At said station II the upper tool unit includes a drawing plunger 31 which registers with the resistance plunger 28 and which upon downward movement serves in cooperation with said ring 30 and said plunger 28 to eiect a relatively deep ydraw of the metal of each blank 24 at said station, the metal flowing downwardly Ias the draw is effected. As the result of the draw, the blank has an approximately vertical wall 32 circular in horizontal section. The blank after said draw has `a `generally horizontal portion extending outwardly from said vertical Wall 32 and joined thereto at the top thereof and also has a generally horizontal portion 33 extending inwardly from said vertical wall 32 and joined thereto at the bottom thereof. At station II the metallic strip initially has the shape indicated by dotted lines. In effecting the draw to Iform the cylindrical or vertical wall 32, each blank 24 is reduced in diameter and the strip 14 is reduced in width. The initial hole in the strip at the right of the station is distorted to the shape shown at 34 and the hole in the strip at the left of the station is distorted to the shape shown at 35.

At station IH the lower tool unit includes a forming plunger 36 which is spring biased upwardly within a stationary ring 38. Upward movement is limited by interengaging shoulders on said plunger and said ring. The

plunger 36 has a central hole which receives and fits a stationary die 40.

At station II-I the upper tool unit includes a forming plunger 42 which registers with a forming plunger 36. The two plungers 36 and 42 have complementaryshapes on theirY upper'and lower faces which serve upon down- Ward movement of the plunger `42 to provide a portion 33 of the blank 24 within the cylindrical or vertical wall 32 with an area 44 shaped to meet the requirements for the end plate A, as shown in FIG. 8. Also carried by the upper tool unit is a punch 46 which cooperates with a die 4) to punch a hole 50 in said blank area 44. A hole 48 is provided for the discharge of the punchings formed by the punch 46. Y

At station IV, as shown in FIG. l, the blank initially has said area 44 shaped as described in connection with station III, and at said station IV the blank is additionally acted upon to provide the required end plate A. At said station IV the lower tool unit includes a stationary member v52 which serves to engage and support the blank near the periphery of said area 44. Carried by the member 52 is a tubular die 54 which serves to engage and support the blank near the center of said area y44. Surrounding the member 52 is an annular resistance member 56 which -is spring biased upwardly. Surrounding the vertically movable member 56 is a stationary annular member 58 which constitutes a die. Upward movement of the member 56 is limited by interengaging shoulders on said member and on the member 58.

At station IV the upper tool unit includes a pressure member 60 which is spring biased downwardly with respect to a supporting member 62 in fixed relationship with the head 12. Said member 62 has a ange 64 which surrounds the member 60. Relative downward movement of the member 60 is limited by one or more headed stop pins 66 engaging the member 62. Surrounding and fitting Ithe member 62 and more particularly the ange 64 thereof is an annular bending to'ol 68, said tool 68 being in fixed relationship with said member 62. The tool 68 is preferably also formed and adapted to effect cutting or severing simultaneously with bending. Carried by the member 62 -in fixed relationship therewith is a punch 70 adapted to cooperate with the stationary die 54. Said punch and die are shaped to provide a notched hole 72 in the end plate A.

As the upper tool unit moves downwardly, the pressure member 60 rst engages the blank at the area 44 thereof and cooperates with the members 52 and `54- to firmly hold said blank in place. As downward movement of the upper tool unit continues, the pressure member 60 yields upwardly, and the annular tool 68 continues downwardly to engage the blank at the periphery of the area 44. The tool 68 serves in cooperation with the member 52 to downwardly bend the peripheral portion of the severed area to form a downwardly projecting annular flange 78. The tool 68 preferably also cooperates with the die member 58 to cut or sever said area 44 from the remainder of the blank, more particularly from the cylindrical wall 32. Severing is effected at a horizontal plane. Substantially simultaneously with the action of the tool 68, the punch 70 engages the blank area y44 and cooperates with the die V54 to enlarge the hole 50 and to yform the notched hole 72.

A hole 79 is provided for the discharge of punchings formed by the punch 70.

The substantially simultaneous action of the tools 68 and 70 completes end plate A. Upon the next following upward movement of the upper tool unit, the completed end plate A is removed in any suitable manner.

After the action of the bending and cutting tool 68, the cylindrical wall 32 remainsl intact and the blank also comprises a complete annulus 7-4 which surrounds said cylindrical vertical wall 32 and is connected by the bands 26, 26 with the leading and trailing blanks of the strip. Severing of the end plate A has been eected with the bottom of the severing cut in a horizontal plane, and preferably the severing has left a narrow annular flange 76 projecting 4 inwardly from the bottom of the cylindrical wall 32. The blank as last above described is moved without change to station V.

At station V, as shown in FIGS. 3, 5, `6 and 7, the lower tool unit includes a stationary member 80 which carries a central button 82. The Vupper face of the button 82 is above the upper face of the member 80 by a distance slightly more than the thickness of the metal of the end ring B which is to be made. Surrounding the member 80 is a ring 84 which is spring biased upwardly, upward movement being limited by one or more headed stop pins 86.

At station V the upper tool unit includes a member 8S which is in xed relationship with the head 12. Vertically movable within the member 88 is a plunger 90, said plunger being biased downwardly to the position shown in FIG. 5 by means of a heavy coil spring 91. Relative downward movement is -limited by interengaging shoulders on said member 88 and said plunger 90. At said station V the upper tool unit also includes a vertically movable ring 92, said ring being guided on the plunger 88 and being spring biased downwardly. Relative downward movement of the ring is limited by one or more headed stop pins 94. The lower ring 84 and the upper ring 92 have annular at faces 96 and 98 at their inner edges which are adapted upon downward movement of the upper ring 92 to engage and pinch the annulus 74 surrounding the cylindrical vertical wall 32.

As the upper tool unit is moved downwardly from the position shown in FIG. 5, the face 98 on the ring 92 engages the annulus 74 and presses the wall 32 downwardly toward the ring 84. Downward movement of the ring 92 continues until said annulus is pinched between the face 96 on the ring 84 and the face 98 on the ring 92. Movement of the ring 92 is momentarily stopped, but is resumed when the bottom face of the member 88 engages the ring 92 as shown in FIG. 6. Thereafter the ring 92 and the plunger 90 move for a short distance in unison, and the ring 84 yields downwardly in accordance with the movement of the ring 92. Downward movement of the plunger 96 is stopped when said plunger engages the button 82, but the rings `92. and 84 continue to move downwardly. The spring 91 yields to permit continued downward movement of the head 12 and the parts attached thereto while the plunger 90 remains stationary.

Referring particularly to FIG. 6, it will be seen that the top face of the member 80 and the bottom face of the plunger 90 define an annular space 100 surrounding the button 82 which space is adapted for the radially inward flow of metal therein. As the rings 92 and 84 move downwardly, the annulus 74 is moved with them without any change or deformation, but the metal in the wall 32 is forced downwardly to the extent permitted by the top face of the member 80. Inasmuch as' downward movement of said metal is limited by said top face, the metal of said wall and of said ange 76 is forced to ow radially inwardly in the annular space 100. FIG. 6 shows an intermediate position wherein the wall 32 has been reduced to 326' and wherein the flange 76 has been increased to 76a. FIG. 7 is similar to FIG. 6, but shows the parts in nal positions, the draw 32 having been reduced to a mere otfset 32b and the flange 76 having been increased to 76b which may extend to the button 82. The space has a thickness only slightly greater than the thickness of the metal and the metal is therefore restrained with respect to any tendency to wrinkle or buckle.

- From the foregoing description it will be apparent that vertical pressure has been applied to the initial vertical wall 32 and that the metal has been simultaneously restrained and guided at a position adjacent the horizontal plane of severing of the plate member A. The metal so restrained and guided flows radially with resultant location of a substantial portion of said vertical wall metal in vertical register with the area of the blank that was occupied by said plate member A before severing thereof. The

metal of the cylindrical vertical wall is thus partially attened.

At station VI, as shown in FIG. 3, the lower tool unit includes a stationary member 102 having a central hole which receives and iits a vertically movable plunger 104, said plunger being spring biased for upward movement to the extent permitted by interengaging shoulders on said member 102 and on said plunger 104.

At station VI the upper tool unit includes a plunger 106 in fixed relationship to the head 12. Fixedly connected with the plunger 106 is a ring 108 having an annular shoulder of such shape and diameter as to engage and fit the offset 32b on the blank. As the upper tool unit moves downwardly, the plunger 106 engages the ange '/'6b of the blank and serves in cooperation with the ring 102 and the plunger 104 to form an annular oset 110 which is required for the end ring B. The iiange 76D, as thus modified, is designated 112.

At station VII, as shown in FIG. 3, the lower tool unit includes a stationary member 114. The upper portion of said member 114 constitutes a die as hereinafter explained. Said member 114 has a hole therein which receives and fits a stationary ring 116 which is shaped at its upper end to engage the oset 110 in the partly `formed end ring B. Said ring 116 serves as a die as hereinafter explained. Also within the hole in the member 114 is a 'vertically movable resistance ring 118 which is spring biased upwardly, upward movement being limited by one or more headed stop pins 120.

At station VII the upper tool unit includes a member 122 in fixed relationship with the head 12. Said member .122 has a downwardly projecting annular flange 124. Surrounding and tting the member 122 and more particularly the flange 124 thereof is an annular bending tool 126, said tool being in iixed relationship with said member 122. Said tool 126 is preferably also formed and adapted for cutting and severing and it has the same effective diameter as to tool 68 at station IV. Carried by the member 122 in iixed relationship therewith is a punch 128 adapted to cooperate with the die 1f16 to trim the interior hole in the flange 112 so as to provide the correct internal diameter -for the end ring B. Also carried by the member 122 and surrounding the punch 128 is a pressure ring 130 which is spring biased downwardly, downward movement being limited by the engagement of the upper portion of said ring with said punch 128.

As the upper tool unit moves downwardly, the pressure ring 130 iirst engages the flange 112 and cooperates with the member 116 to hold the partly completed end ring B in place. As downward movement of the upper tool unit continues, the pressure ring 130 yields upwardly and the annular tool 126 engages the annulus 74 approximately at -the offset 32h. The tool 126 serves in cooperation with the member 1'16 to downwardly bend the peripheral portion of the end ring B to form a downwardly projecting annular flange 136. The tool 126 also cooperates with the die 114 to sever the end ring B from the annulus 74, leaving narrow bands 134 which are connected with the longitudinal bands 26, 26.

Substantially simultaneously with the action of the severing tool 126, the punch 128 engages the flange 112 and cooperates with the die 116 to trim said ange to provide a narrower flange 112e, the interior diameter of which is the required interior diameter of the end ring B. Punchings are discharged through the die ring 116 and through suitable holes 138.

The substantially simultaneous action of the tools 126 and 128 completes the end ring B. Upon `the next following upward movement of the upper tool unit, the completed end ring is removed in any suitable manner.

FIG. 8 is an exploded perspective view showing the end plate A and the end ring B in positions for assembly with a blade unit C which is shown in phantom. The blade unit C ordinarily comprises a metallic strip having blades formed integrally therefrom, said strip being bent to cylindrical form. The edges of the blade strip are entered in the spaces in the end plate and in the end ring within the flanges 78 and 136 thereof, and said flanges are then crimped to hold the parts in assembled relationship.

Summarizing as to the method of making the companion sheet metal end members which are the end plate A and end ring B, it will be seen that a blank 24 is provided and that at station II a deep draw is eected in said blank to produce an approximately cylindrical or vertical wall 32 joined at the top end thereof to an outwardly extending generally horizontal blank portion and joined at the bottom end thereof to an inwardly extending generally horizontal blank portion. At station IV one of said members A and B is finally shaped from one of said generally horizontal blank portions immediately adjacent said cylindrical or vertical wall 32. As shown, it is the end plate A that is so shaped and it is shaped from the inwardly extending blank portion 33, but the invention is not so limited. The formed end member, such as A, is severed from said cylindrical wall 32, said end member being preferably severed at said station IV.

At station V vertical pressure is applied to the metal of the cylindrical or vertical wall 32 at the end of said wall which is opposite said plane of severing, said pressure being directed toward said plane. The metal at a position adjacent the plane of `severing is restrained and guided so as to be caused to flow radially as shown in FIGS. 6 and 7 and as already fully described. As shown, downward pressure is applied to the metal of said wall at the top thereof, and the metal of said vertical wall is caused to flow radially inwardly. At station VII the remaining member, which may be the ring B, is formed or shaped from the metal that has been caused to flow radially from the vertical wall. Also at station VII the formed end member, such as B, is severed from the remainder of the blank.

Causing radial ow of portions of the wall 32, as described in connection with station V, makes it possible for the end ring B to have the same exterior diameter as the end plate A and to also have sufficient metal for the flange 112B.

Preferably and as shown, the several method steps are effected in timed sequence, the cutting of the holes 20 providing a series of blanks 24 which are uniformly spaced longitudinally and are connected with each other by narrow longitudinal bands 26, 26 at the edges of the strip 14.

For convenience of description, terms such as horizontal, vertical, top and bottom are used with reference to the several sheet metal portions, but these terms merely designate the relationship of the said portions and do not limit the scope of the invention.

The invention claimed is:

l. rl'he hereindescribed method of making a pair of companion sheet metal members which members have approximately the same external diameter and are respectively a circular plate and a circular ring, said method comprising the following steps in sequence: effecting a deep draw in a horizontal sheet metal blank to produce an approximately vertical wall circular in horizontal section which blank after said draw has a generally horizontal portion extending outwardly from said vertical wall and joined thereto at the top thereof and also has a generally horizontal portion extending inwardly from said vertical wall and joined thereto at the bottom thereof, shaping one of said members from one of said generally horizontal portions of the blank at a position immediately adjacent said vertical wall and concentric therewith which shaping is effected while the last said horizontal portion is in fixed relationship to said wall, severing said shaped member from said vertical wall at a horizontal plane of severing, applying vertical pressure to the metal of the vertical wall at the end thereof opposite said plane of severing which pressureis directed toward said plane,

restraining andguiding the metal ofrsaid vertical wall at a position adjacent said horizontal plane of severing Vso that said applied pressure causes a substantial portion of saidV metal to flow radially 'with resultant location thereof in a substantially horizontal position and in vertical register with the area ofthe blank that was occupied by the first said memberV before severing thereof, shaping the other of said members at least in part from the last said horizontally positioned metal, the last said other member having an external diameter approximately the same as that of the lirst said member, and severing said other shaped member from the remainder of the metal blank.

2. The hereindescribed method of making a pair of companion sheetrmetal members which members have approximately the same external diameter and are respectively a circular plate and acircular ring, said method comprising the following steps in sequence: effecting a deep draw in a horizontal sheet metal blank to produce an approximately vertical wall circular in horizontal section which blank after said `draw has a generally horizontal portion extending outwardly from said vertical wall and joined thereto at the top thereof and also has a generally horizontal portion extending inwardly from said vertical wall and joined thereto at the bottom thereof, shaping the plate member from said inwardly extending generally horizontal portion of the blank at a position concentric with said vertical wall which shaping is etected while said inwardly extending horizontal portion is in fixed relationship to said wall, severing said shaped plate member from said vertical wall at a horizontal plane of severing, applying downward vertical pressure to the metal of the vertical wall at the top end thereof, restraining and guiding the metal of said vertical Wall at a position Vadjacent said horizontal plane of severing so that said applied pressure causes a substantial portion of said metal to flow radially inwardly with resultant location thereof in -a substantially horizontal position, shaping the ring member at least in part from the last said horizontally positioned metal, said ring member having an external diameter approximately the same as that of the plate member, and severing said shaped ring member from the remainder of the metal blank.

3. 'Ille hereindescribed method of making a series of pairs of companion sheet metal members which members of each pair have approximately the same external diameter and are respectively a circular plate and a circular ring, said method comprising the following steps in combination: cutting a horizontal sheet metal strip to provide a series of blanks which are uniformly spaced longitudinally and are connected with each other by narrow longitudinal bands at the edges of the strip, intermittently moving the strip longitudinally to bring said blanks successively to a series of operating stations, at one station effecting a deep draw in each blank to produce an approximately vertical Wall circular in horizontal section which blank after said draw has a generally horizontal portion extending outwardly from said vertical wall and joined thereto at the top thereof and also has a generally horizontal portion extending inwardly from said vertical wall and joined thereto at the bottom thereof, at a subsequent station shaping the plate member from said inwardly extending generally horizontal portion of Vthe blank at a position concentric with said vertical wall which shaping is effected while said inwardly extending horizontal portion is in fixed relationship to said vertical wall, severing said shaped plate member from said vertical wall, at a subsequent station and while the blank remains connected with said longitudinal bands applying downward vertical pressure to the metal of the vertical wall at the top thereof, restraining and guiding the metal of said vertical wall at a position adjacent said horizontal plane of severing so that said applied pressure causes a substantial portion of said metal to ow radially inwardly, at a subsequent station and while the blank remains connected with said longitudinal bands shaping the ring member at least in part from thelast said horizontally positioned metal, said ring member having an external diameter approximately the same as that of the plate member, and severing said shaped ring member from the remainder of the corresponding blank.

4. The hereindescribed method of making a series of pairs of comp-anion sheet metal members which members of each pair have approximately the same external diameter and Iare respectively a circular plate and a circular ring, said method comprising the following steps in combination: cutting a horizontal sheet metal strip to provide a series of blanks which are uniformly spaced longitudinally and are connected with each other by narrow longitudinal bands at the edges ofthe strip, intermittently moving the strip longitudinally to bring said blanks successively to a series of operating stations, at one station elfecting a deep draw in each blank to produce an approximately vertical wall circular in horizontal section which blank after said draw has a generally horizontal portion extending outwardly from said vertical wall and joined thereto at the top thereof and also has a generally horizontal portion extending inwardly from said vertical wall and joined thereto at the bottom thereof, at a subsequent station shaping the plate member from said inwardly extending generally horizontal portions of the blank at a position concentric with said vertical wall which shaping is effected while said inwardly extending horizontal portion is in fixed relationship to said vertical wall, at the last said station severing said shaped plate member from said vertical wall, at a subsequent station and while the blank remains connected with said'longitudinal bands applying downward vertical pressure to the metal of the vertical wall at the top end thereof, restraining `and guiding the metal of said vertical wall at a position adjacent said horizontal plane of severing so that said applied pressure causes a substantial portion of said metal to flow radially inwardly, at a subsequent station and while the blank remains connected with said longitudinal bands shaping the ring member at least in part from the last said horizontally positioned metal, said ring member having an external diameter approximately the same as that of the plate member, and at the last said station severing said shaped ring member from the remainder of the corresponding blank.

References Cited in the file of this patent UNITED STATES PATENTS 1,040,274 Chambers Oct. 8, 1912 1,257,502 Leighton Feb. 26, 1918 1,884,699 Hothersall Oct. 25, 1932 2,016,225 Bukolt Oct. 1, 1935 2,430,437 Trautvetter Nov. 4, 1947 rek. 'n 

